1

Transfer Case Nuts

Special Tools

J 45759 Assembly Fixture

2

Transfer Case

Special Tools

J 3289-20 Holding Fixture

3

Pivot Pin

Tip

1

Transfer Case Access Hole Plugs (Qty: 2)

2

Transfer Case Oil Fill Plug

3

Transfer Case Oil Drain Plug

4

Transfer Case Control Lever Bolt/Screw

5

Transfer Case Lever

6

Transfer Case Shift Lever Washer

7

Transfer Case Vent

Tip
Remove ONLY if the vent pipe is damaged.

8

Transfer Case Shift Control Switch Assembly

9

Transfer Case Selector Switch - O-ring - Seal

10

Vehicle Speed Sensor Assembly

11

Vehicle Speed Sensor O-Ring Seal

1

Transfer Case Rear Output Shaft Seal

Notice: Refer to Transfer Case Seal Removal Notice in the Preface section.

2

Transfer Case Rear Output Shaft Bushing

Tip

Special Tools

J 45380 Transfer Case Rear Bushing Remover and Installer

1

Transfer Case Bolts (Qty: 17)

2

Transfer Case Bracket

3

Transfer Case Rear Case Half

Notice: Refer to Machined Surface Damage Notice in the Preface section.

Tip

4

Transfer Case Front Output Shaft Driven Sprocket Spacer Spring

5

Transfer Case Front Output Shaft Driven Sprocket Spacer

1

Transfer Case Oil Pump Suction Pipe

2

Transfer Case Oil Pump Suction Pipe Seal

3

Transfer Case Shift Fork Spring

4

Transfer Case Control Actuator Shaft

5

Transfer Case Two/Four Wheel Drive Shift Fork Assembly

6

Transfer Case High/Low Shift Fork

1

Transfer Case Front Output Shaft Driven Sprocket

2

Transfer Case Rear Output Shaft Assembly

Tip
Mount the assembly into a soft-jaw vice or holding fixture for disassembly.

3

Transfer Case Front Output Shaft Drive Chain Assembly

4

Transfer Case High/Low Clutch

5

Transfer Case Rear Output Shaft Rear Bearing Retaining Ring

6

Transfer Case Rear Output Shaft Rear Bearing Assembly

Tip
Use an arbor press or suitable puller to remove the bearing from the rear output shaft.

7

Transfer Case Rear Output Shaft Rear Bearing Retaining Ring

8

Transfer Case Rear Output Shaft Speed Reluctor Wheel

9

Transfer Case Oil Pump Assembly

10

Transfer Case Front Output Shaft Drive Sprocket Retaining Ring

11

Transfer Case Front Output Shaft Drive Sprocket Spacer - Rear

12

Transfer Case Front Output Shaft Drive Sprocket

13

Transfer Case Front Output Shaft Drive Sprocket Bearing Assembly (Qty: 2)

Tip
Only remove the bearing if faulty. Refer to Drive Chain, Drive Sprocket, and Driven Sprocket Cleaning and Inspection.

14

Transfer Case Two/Four Wheel Drive Synchronizer Blocking - Inner - Ring

15

Transfer Case Two/Four Wheel Drive Synchronizer Blocking - Outer - Ring

16

Transfer Case Two/Four Wheel Drive Synchronizer Assembly

17

Transfer Case Two/Four Wheel Drive Synchronizer Sleeve

18

Transfer Case Two/Four Wheel Drive Synchronizer Insert (Qty: 3)

19

Transfer Case Two/Four Wheel Drive Synchronizer Hub

1

Transfer Case Shift Detent Plunger Plug

2

Transfer Case Shift Detent Plunger Plug Seal

3

Transfer Case Shift Detent Spring

4

Transfer Case Shift Detent Plunger

5

Transfer Case Shift Detent Lever Assembly

6

Transfer Case Shift Lever Seal

7

Transfer Case Input Shaft Seal

8

Transfer Case Input Shaft Bearing Outer Retaining Ring

Caution: Do not rotate the transfer case while the retaining ring is removed. Rotating the transfer case while the retaining ring is removed, may cause the input shaft/planetary assembly to fall from the transfer case, resulting in personal injury.

9

Transfer Case Input Shaft/Planetary Assembly

10

Transfer Case High/Low Planetary Carrier Retaining Ring

11

Transfer Case High/Low Locking Plate

12

Transfer Case Planetary Carrier Sun Gear Thrust Washer

13

Transfer Case Input Shaft

14

Transfer Case Input Shaft Pilot Bearing Assembly

Tip
Only remove the bearing if faulty.

Refer to Front Output Shaft and Input Shaft Cleaning and Inspection.

15

Transfer Case Planetary Carrier Sun Gear Thrust Washer

16

Transfer Case High/Low Planetary Carrier Assembly

17

Transfer Case Input Shaft Inner Retaining Ring

18

Transfer Case Input Shaft Bearing Assembly

1

Transfer Case Front Case Half

Tip
Place the front case half on an arbor press.

2

Transfer Case Front Output Shaft Assembly

Tip
Press the front output shaft assembly from the front case half using an arbor press or soft-face hammer.

3

Transfer Case Front Output Shaft Seal